®

XF/EP/HP/XP 40/50
OPERATORS/INSTRUCTION
MANUAL AND PARTS LIST

Before installation or starting the compressor for the

first time, this manual should be studied carefully to
obtain a clear knowledge of the unit and of the duties
to be performed while operating and maintaining the
unit.

RETAIN THIS MANUAL WITH UNIT.

This Technical manual contains IMPORTANT SAFETY
DATA and should be kept with the air compressor at all
times.

Ingersoll-Rand (I) Ltd.,

EFFECTIVE
Peenya Industrial Area,
Peenya, FROM June, 2000
Bangalore 560 058 TO
INDIA PAN-IBPL (R0)
June, 2000
 ROTARY SCREW COMPRESSOR
This unit was purchased from:
_________________________________________
_________________________________________

Ingersoll Rand reserves the right to make changes

or add improvements without notice and without
incurring any obligation to make such changes or
add such improvements to products sold previously.

For ready reference record the serial number and

model number of your unit here

Serial Number:____________________________

Model Number:____________________________

TYPICAL UNIT

1
 TABLE OF CONTENTS

0.0 SAFETY AND WARNINGS 7.0 OPTIONS

0.1 Safety Instructions 7.1 Remote start/stop
0.2 Safety Procedures 7.2 Remote start/stop & Power Outage
0.3 Decals restart
1.0 RECEIPT OF THE EQUIPMENT 7.3 Modulation Control
7.4 High Dust Filtration
1.1 Inspection
1.2 Unpacking and Handling 8.0 REFERENCE DRAWINGS
1.3 Tools 8.1 Electrical, schematic
2.0 INSTALLATION 8.2 Foundation Plan
8.3 Basic Flow, schematic
2.1 Ventilation 8.4 Typical System Flow Diagrams
2.2 Foundation Requirements
2.3 Piping 9.0 MAINTENANCE RECORDS
2.4 Electrical Installation
2.5 Outdoor Sheltered Installation
3.0 INTELLISYS
3.1 Emergency Stop Switch
3.2 Power on Light
3.3 Power Indicator Light
3.4 Push Buttons
3.5 Set Point Procedure
3.6 Warnings GENERAL INFORMATION
3.7 Alarms
Weight
4.0 SYSTEMS See foundation plan, Section 8.0
4.1 General System Information Cooling Air flow
4.2 Air Cooled Compressors See foundation plan, Section 8.0
4.3 Coolant System Ambient Temperature Limit
4.4 Compressed Air System 2°C to 46°C (35°F to 115°F)
4.5 Coolant/air Seperation System Coolant
4.6 Electrical System Factory filled SSR Ultra coolant
5.0 SCHEDULED PREVENTIVE Coolant Change
MAINTENANCE 8000 hours or two years, whichever comes first
Coolant Capacity
5.1 Maintenance Schedule
12.9 liters (3.4 gals)
5.2 Maintenance Records
Discharge Temperature Limit
5.3 Maintenance Procedures
109°C (228°F)
5.4 Sheave Alignment
Power Inlet Wiring, Recommended Conduit:
5.5 V-Belts
Metallic flexible or equlant
5.6 Autamatic Belt Tensioner Service
Tools
5.7 Shaft Seal Replacement
Standard tools
5.8 Inlet Air Filter
5.9 Coolant Filter Element
5.10 Coolant
5.11 Separator Tank Scavenge
5.12 temperature Control valve Element
5.13 Coolant Separator Element
5.14 Coler Cores
5.15 Motor lubrication
5.16 Intellisys Removal
5.17 Coolant Hoses
5.18 Airend Discharge Hose
6.0 TROUBLE SHOOTING

2
0.0 SAFETY AND WARNINGS
0.1 SAFETY INSTRUCTIONS
Before you install this air compressor you should
take the time to carefully read all the instructions
contained in this manual.
Electricity and compressed air have the potential to
cause severe personal injury or property damage.
Danger is used to indicate the presence
of a hazard which will cause severe
! DANGER
personal injury, death, or substantial
property damage if the warning is
ignored.

Before installing, wiring, starting, operating or Warning is used to indicate the

making any adjustments, identify the components of presence of a hazard which can cause
the air compressor using this manual as a guide. ! WARNING severe personal injury, death, or
The operator should use common sense and good substantial property damage if the
working practices while operating and maintaining warning is ignored.
this unit. Follow all codes, pipe adequately,
understand the starting and stopping sequence. Caution is used to indicate the
Check the safety devices by following the procedure presence of a hazard which will or can
contained in this manual. cause minor personal injury or
! CAUTION property damage if the warning is
Maintenance should be done by qualified personnel, ignored.
adequately equipped with proper tools. Follow the
maintenance schedules as outlined in the operators Notice is used to notify people of
manual to ensure problem free operation after start installation, operation, or maintenance
up. NOTICE information which is important but not
hazard-related.
Safety instructions in the operators manual are bold-
faced for emphasis. The signal words DANGER,
WARNING and CAUTION are used to indicate hazard
seriousness levels as follows:
0.2 SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
BEFORE PROCEEDING, READ CAREFULLY BEFORE INSTALLING THE
COMPRESSOR OR PERFORMING ANY MAINTENANCE
WARNING
3. Do not operate the compressor at
COMPRESSED AIR AND ELECTRICITY c.) Vent pressure from the compressor
higher discharge pressure than those and isolate the unit from any other
ARE DANGEROUS.
specified on the Compressor source of air.
Nameplate or motor overload will
BEFORE DOING ANY WORK ON THIS
occur. This condition will result in 8. There can be adverse effects if
UNIT, BE SURE THE ELECTRICAL
compressor motor shutdown. compressor lubricants are allowed to
SUPPLY HAS BEEN CUT OFF–
LOCKED & TAGGED AND THE ENTIRE enter plant air systems.
4. Use only safety solvent for cleaning
COMPRESSOR SYSTEM HAS BEEN
the compressor and auxiliary Air line separators, properly selected
VENTED OF ALL PRESSURE.
equipment.
and installed, will minimize any liquid
1. Do not remove the covers, loosen or carry-over.
5. Install a manual shut off valve
remove any fittings, connections or
(isolation type) in the discharge line.
devices when this unit is in operation. The use of plastic bowls on line filters
When a safety valve is installed without metal guards can be
Hot liquid and air under pressure that
between the isolation valve and the hazardous. From a safety standpoint,
are contained within this unit can
compressor, it must have sufficient
cause severe injury or death. metal bowls should be used on any
capacity to relieve the full capacity of pressurized system. Review of your
the compressor(s). plant air line system is recommended.
2. The compressor has high and
dangerous voltage in the motor starter
6. Whenever pressure is released 9. When a receiver is installed, it is
and control box. All installations must
through the pressure relief valve, it is recommended that occupational safety
be in accordance with recognized
due to excessive pressure in the
electrical codes. Before working on the and health standards be adhered to in
system. The cause for the excessive the installation and maintenance of
electrical system, be sure to remove
pressure should be investigated this receiver.
voltage from the system by use of a
immediately.
manual-disconnect-switch. A circuit
breaker or fuse safety switch must be 10. Before starting the compressor, its
7. Before doing any mechanical work maintenance instructions should be
provided in the electrical supply line
on the compressor:
leading to the compressor. thoroughly read and understood.
a.) Shut the unit down. 11. After maintenance functions are
Those responsible for installation of
this equipment must provide suitable completed, covers and guards must be
b.) Electrically isolate the compressor replaced.
grounds, maintenance clearance and
by use of the manual disconnect
lightning arrestors for all electrical
switch in the power line to the unit.
components as stipulated in Indian
Lock and tag the switch so that it
Electricity Rules.
cannot be operated.
3
 ! SAFETY SHUTDOWN
CHECK HIGH AIT TEMPERATURE
There is a high discharge air temperature shutdown function built into the Intellisys on each
compressor. It is factory pre-set at 109°C (228°F). The function should be checked at regular
intervals for proper operation, once a month is recommended. The procedure is:
1. Block off the cooling air discharge.
2. The compressor discharge temperature will raise at a rapid rate. Shutdown should occur
when the discharge temperature reaches the pre-set maximum discharge air
temperature setting of the Intellisys. The display should indicate “HIGH AIREND TEMP”
and the alarm light will be illuminated.
The actual temperature at which shutdown occurs should be recorded for comparision to the
Intellisys set point and with similar future test results.

! WARNING
Failure to adhere to these recommendations can result in mechanical failure, property damage and
serious injury or death.
All air and water inlet, air and water discharge pipework to and from the inlet and discharge port
connections must take into account vibration, pulsations, temperature, maximum pressure applied,
corrosion and chemical resistance. In addition, it should be noted that lubricated compressors will
discharge some oil into the airstream; therefore, compatibility between discharge piping, system
accesories and software must be assured.
For the foregoing reasons, the use of plastic piping soldered copper fittings and rubber hose as
discharge piping is not recommended. In addition, flexible joints and/or flex lines can only be
considered for such purposes if their specifications fit the operating parameters of the system.
It is the responsibility of the installer and owner to provide the appropriate service pipework to and
from the machine.

! WARNING
“Ingersoll-Rand air compressors are not designed, intended or approved for breathing air
applications. Ingersoll-Rand does not approve specialised equipment for breathing air
application and assumes no responsibility or liability for compressors used for breathing
air services.”

4
0.3 DECALS
This section contains representative examples of
decals which will be appearing throught this manual
and are applied to the compressor unit. If for some
reason a decal is defaced, painted over or parts are
replaced, we recommend that you obtain a
replacement kit as listed in the parts llist section of
this manual.

5
6
7
8
9
NOTES:

10
1.0 RECEIPT OF EQUIPMENT
1.1 INSPECTION
When you receive the compressor please inspect it
closely. Any indication of careless handling by the
carrier should be noted on the delivery receipt
especially if the compressor will not be immediately
uncrated. Obtaining the delivery man’s signed
agreement to any noted damages will facilitate any
future insurance claims.

IMPORTANT
READ THIS
LOST OR DAMAGED GOODS

THOROUGHLY INSPECT THIS SHIPMENT

IMMEDIATELY UPON ARRIVAL

OUR RESPONSIBILITY FOR THIS SHIPMENT

CEASED WHEN THE CARRIER SIGNED
BILL OF LADING
If goods are received short or in damaged condition, it is important
that you notify the carrier and insist on a notation of the loss or
damage across the face of the freight bill. Otherwise no claim can be
enforced against the transportation company.

If concealed loss or damage is discovered, notify your carrier at once

and request an inspection. This is absolutely necessary. Unless you
do this the carrier will not entertain any claim for loss or damage. The
agent will make an inspection and grant a concealed damage
notation. If you give the transportation company a clear receipt for
goods that have been damaged or lost in transit, you do so at your
own risk and expense.

WE, AT I-R, ARE WILLING TO ASSIST YOU IN EVERY POSSIBLE

MANNER TO COLLECT CLAIMS FOR LOSS OR DAMAGE, BUT
THE WILLINGNESS ON OUR PART DOES NOT MAKE US
RESPONSIBLE FOR COLLECTION OF CLAIMS OR
REPLACEMENT OF MATERIAL. THE ACTUAL FILING AND
PROCESSING OF THE CLAIM IS YOUR RESPONSIBILITY.

Ingersoll-Rand (I) Ltd.

Bangalore

1.2 UNPACKING AND HANDLING

The compressor package has been mounted on a
base which provides for forklifting between the two
side channels to facilitate handling during shipment.
Care in positioning the forklifts is important because
the location of the center of gravity is strongly
affected by the location of the compression module
and drive motor.
Slings can be used to lift the crates, but spreader
bars must be used to prevent the slings from
exerting a force against the sides of the crates.
1.3 TOOLS
Remove compressor unit from wooden skid. A
crowbar and hammer will be needed.

11
NOTES:

12
2.0 INSTALLATION
2.1 VENTILATION
Oil flooded rotary air compressors produce large
amounts of heat. Because of this large heat
production, the compressor must be placed in a
room with adequate ventilation. A room in which the
amount of air that is drawn in and exhausted is
equal to or greater than the cooling fan air flow
requirement for the compressor that is installed.
If heated air from the compressor exhaust is allowed
to recirculate back to the compressor, the
compressor will overheat and shut down. This heat
must be exhausted from the room. You should
take this into consideration when you decide where
to place the compressor within your plant. Consider
that the required maintenance clearance is 0.9m
(3ft.) all around the compressor. However 42”
(1.06m), or minimum required or applicable local
codes, must be maintained in front of control panel.
Ambient temperatures higher than 46°C (115°F)
should be avoided as well as areas of high
humidity.
Consider also the environment surrounding or
near the compressor. The area selected for the
location of the compressor should be free of
dust, chemicals, metal filings, paint fumes and
overspray.

DUST CHEMICALS

METAL PAINT
FILLINGS SPRAY

OVERSPRAY 2.3 PIPING

2.2 FOUNDATION REQUIREMENTS
Refer to the foundation plan for the particular model
compressor to be installed. See Section 8.0
The compressor can be installed on any level floor
that is capable of supporting it. Compressor weights
are listed on the foundation plans.
When sound transmission is of particular importance
it is often helpful to install a sheet of rubber-fabric-
matting, or cork under the compressor to reduce the
possibility of resonant sounds being transmitted or
amplified through the floor.
The use of plastic bowls on line filters without metal
guards can be hazardous. Their safety can be
affected by either synthetic lubricants or the
additives used in mineral oil. From a safety
standpoint, metal bowls should be used on any
pressurized system. Review of your plant air line
system is recommended.
! WARNING
Do not use plastic pipe, soldered
copper fittings or rubber hose for
discharge piping.

! NOTICE
Never elevate the compressor unit
above the floor level. This may allow
air to enter the cabinet under the
base. Performance will be affected.
The built-in aftercooler reduces the discharge air
temperature well below the dew point (for most
ambient conditions), therefore, considerable water
vapor is condensed. To remove this condensation,
each compressor with built-in aftercooler is furnished
with a combination condensate separator/trap.

13
2.3 PIPING (Continued)
A dripleg assembly and isolation valve should be
mounted near the compressor discharge. A drain
line should be connected to the condensate drain in
the base.
IMPORTANT: The drain line must slope downward
from the base to work properly.
NOTE: For ease of inspection of the automatic
drain trap operation, the drain piping should include
an open funnel.
It is possible that additional condensation can occur
if the downstream piping cools the air even further
and low points in the piping systems should be
provided with driplegs and traps.
IMPORTANT: Discharge piping should be at least
as large as the discharge connection at the
compressor enclosure. All piping and fittings must
be suitable for the maximum operating temperature
of the unit and, at a minimum, rated for the same
pressure as the compressor sump tank.

! NOTICE
Do not use the compressor to
support the discharge pipe.

Careful review of piping size from the compressor

connection point is essential. Length of pipe, size of
pipe, number and type of fittings and valves must be
considered for optimum efficiency of your
compressor.
It is essential when installing a new compressor to
review the total plant air system. This is to ensure a
safe and effective total system.
Liquid water occurs naturally in air lines as a result
of compression. Moisture vapor in ambient air is
concentrated when pressurized and condenses
when cooled in downstream air piping.
Moisture in compressed air is responsible for costly
problems in almost every application that relies on
compressed air. Some common problems caused by
moisture are rusting and scaling in pipelines,
clogging of instruments, sticking of control valves,
and freezing of outdoor compressed air lines. Any of
these could result in partial or total plant shutdown.
Compressed air dryers reduce the water vapor con-
centration and prevent liquid water formation in
compressed air lines. Dryers are a necessary com-
panion to filters, aftercoolers, and automatic drains
for improving the productivity of compressed air
systems.

14
Two types of dryers, refrigerated or desiccant, are
used to correct moisture related problems in a com-
pressed air system. Refrigerated dryers are normally
specified where compressed air pressure dew points
of 1°C (33°F) to 4°C (39°F) are adequate.
Desiccant dryers are required where pressure dew
points must be below 1°C (33°F).
Contact your local Ingersoll-Rand distributor for
assistance in selecting correct Ingersoll-Rand filtra-
tion or drying products.
NOTE: Screw type compressors should not be
installed in air systems with reciprocating
compressors without a means of pulsation isolation,
such as a common receiver tank. We recommend
both types of compressor units be piped to a com-
mon receiver utilizing individual air lines.
When two rotary units are operated in parallel,
provide an isolation valve and drain trap for each
compressor before the common receiver.

2.4 ELECTRICAL-INSTALLATION

Before proceeding further, we recommend that

you review the safety data in the front of this
manual.

Locate the compressor data plate on the left rear

corner of the unit. ROTARY TWO COMPRESSOR SYSTEM

The data plate lists the rated operating pressure, the

maximum discharge pressure and the electric motor
characteristics and power.

Confirm that the line voltage and compressor

nameplate voltage are the same and that the stan-
dard starter box meets the intent of IS guidelines.

Open the starter box door. Confirm that all electrical

connections are made and tightened. Confirm that
the control transformer is wired correctly for supply
voltage. See figure 2.4.1 on next page for typical
control transformer wiring.

1FU 2FU 3FU 4FU/5FU

Control
Primary Primary Secondary Secondary
Transformer
fuse fuse fuse fuse
(VA)
(Amp) (Amp) (Amp) (Amp)

350 4.0 4.0 6.0 2.0

15
ELECTRICAL INSTALLATION (Continued)
Inspect the motor and control wiring for tightness.
Close and fasten the starter box door.
Rotation Check
Locate the rotation decal on each motor.
Drive Motor
The correct compressor drive motor rotation is
clockwise when viewed from the rear or non-
drive end of the motor. See figure 2.4.2

! CAUTION Fig. 2.4.2 Drive Motor Rotation

If the compressor is operated in the

opposite direction of rotation, airend
damage can result and is not
warrantable.

16
ELECTRICAL-INSTALLATION (Continued)
The Intellisys will automatically shut the unit down if
the compressor rotation is incorrect, and “CHK MTR
ROTATION” will appear in the display, also the alarm
light will be on. See Section 6.
For the compressor motor rotation check, the motor
jogging time must be as short as possible.
After depressing the start button, IMMEDIATELY
depress the “EMERGENCY STOP” button.
Should the motor rotation be incorrect, put main
disconnect in the OFF position, lock and tag.
See Figure 2.4-3.

Figure 2.4.3 Main Disconnect

Locked and Tagged.

Open the starter box door.

Interchange any two line connections (L1, L2 or L3)
at the starter. Close and fasten the starter box door.
Recheck for correct rotation.
Fan Motor Figure 2.4.4 Intellisys
Operating Instructions.
Observe the compressor cooling fan. The rotation
should be in accordance with the fan rotation decal
affixed to the fan motor. Cooling air should exhaust
through top of compressor enclosure.
Should the motor rotation not be correct, put the
main disconnect in the OFF position, lock and tag.
Interchange any two fan motor leads at the fan
motor overload relay (2OL). Close and fasten the
starter box door. Recheck for correct rotation.
Intellisys Operating Instructions
Read and understand the following Intellisys
Operating Instructions (See figure 2.4.4 prior to
operating the unit.
Note: These instructions are also contained on the
decal near the Intellisys panel of the unit.

17
2.5 OUTDOOR SHELTERED INSTALLATION

Many times a compressor must be installed outside

due to jobsite conditions or limited space within a
mnufacturing facility. When this occurs there are
certain items that should be incorporated into the
installation to help ensure trouble free operation.
These items have been listed below plus Figure
2.5-1 has been included to show a typical outdoor
sheltered installation.The unit must be purchased
with the Outdoor Modification Option to provide
NEMA 4 electrics and a cabinet exhaust on the rear
of the unit rather than the top to prevent recir-
culation of cooling air.
n The compressor should be on a concrete
pad designed to drain water away. If the
concrete pad is sloped, then the compres-
sor must be leveled . In order to properly
pull cooling air through the aftercooler, the
base/skid must be sealed to the concrete
pad.
n Incoming power connections must use
suitable connectors for outdoor weather
tight service.
n A minimum of 3 ft (.9m) clearance must be
allowed on all four sides of the unit for
service access. However 42” (1.06m) or
minimum required by latest applicable local
code, must be maintained in front of control
panel.
n If possible, access by a forklift and/or an
overhead beam hoist should be kept in
mind (for eventual service to airend or
motor).
n If the area around the installation contains
fine airborne dust or lint and fibers etc.,
then the unit should be purchased with the
High Dust Filter Option.

n The roof of the shelter should extend a n Some type of protection such as a fence or
minimum of 4 ft (1.2 m) around all sides of security system, should be provided to
the compressor to prevent direct rain and prevent unauthorized access.
snow from falling on the unit.
n Air-cooled machines must be arranged
under the shelter in a way that prevents air
recirculation (i.e. hot exhaust back to the
package inlet).
n If the installation includes more than one
compressor, the hot air exhaust should not
be directed towards the fresh air intake of
the second unit or an Air Dryer.
n If a standard machine is to be installed
outside, the ambient temperature must
never drop below 1.7°C (35°F).
n Arrange the machine with the Intellisys
controller/starter enclosure facing away
from the sun as radiant heat can affect
starter/lntellisys performance.
n Also direct sunlight and UV rays will
degrade the membrane touch panel.This is
not a warrantable situation.
n Power disconnect switch should be within
line of sight and in close proximity to the
unit. Local electrical codes must be fol-
lowed when installing the power disconnect
switch.
n Condensate drains must never be allowed
to dump on the ground. Run to a suitable
sump for future collection and disposal or
separation of lubricant and water mixture.

18
19
NOTES:

20
 3.0 INTELLISYS

21
INTELLISYS CONTROLLER
3.0 INTELLISYS

3.1 EMERGENCY STOP SWITCH UNLOADED STOP

Pressing this switch stops the compressor
immediately. Compressor cannot be restarted
until switch is manually reset. Turn clockwise to
reset.
Pressing this button will activate the unload stop.
If the compressor is running loaded, it will
unload. Seven seconds later it will stop. If the
compressor is running unloaded, it will stop
immediately. Pressing this button with the unit
stopped will flash all L.E.D.’s for a light check and
flash the software version number in the display.

3.2 POWER ON LIGHT (Inside Starter Box)

Indicates control voltage is available to the

control circuit and line voltage is available for UNLOAD/LOAD
starting.
If the unit is running loaded, pressing this button
will cause the unit to unload, the unload indicator
POWER light will be on. The unit will not load until the
ON button is pressed again. If the unit is running
unloaded, pressing this button will load the unit in
the ON/OFF LINE or MOD/ACS control mode
3.3 POWER INDICATOR LIGHT previously operating.

Indicates voltage is available to the intellisys

controller.

3.4 PUSH BUTTONS

START

If the display shows READY TO START, pressing

this button will start the compressor. The
compressor will start and load automatically if
there is a demand for air.

If in the display table, press this button to exit the

display table. Display will show “CHECKING
MACHINE”, then “READY TO START”.

22
3.4 PUSH BUTTONS (Continued)
PRESSURE SENSOR CALIBRATION
DISPLAY SELECT (ZEROING) ROUTINE

Pressing this button will change the information
selected for the display. The display table will be
incremented. If the button is held, this display
table will scroll. This button can also be used to
exit the set point procedure.
This routine is entered if the unit is not running
and both the up and down arrows button are
pressed at the same time. Make sure all
pressure is relieved from the compressor before
calibration. The display will flash the message
“CALIBRATING”. After calibration is completed,
the display will indicate “READY TO START”.
Zeroing should only be done after a pressure
sensor has been replaced or any controller
change.

NOTE: For readings less than 1 hr., hourmeter

displays minutes. After 1 hr. the hourmeter
displays hours.

SET

The SET button is used to enter the set point

procedure. The set button is also used to reset
warnings and alarms. Pressing this button once
will reset a warning, twice will clear an alarm.

ARROWS

These buttons have several functions. If the

Intellisys is in the set point mode, the ARROWS
are used to change the set point values. If the
unit has multiple alarms or warnings, the
ARROWS are used to scroll through these
conditions. The ARROWS have a function in the
calibration routine, which will be described later.

23
3.5 SET POINT PROCEDURE
This procedure allows the customer to modify 11
variables in the controller logic.
At this time, press the SET button to enter the
set point routine. The SET OFFLINE AIR
PRESSURE indicator will light and the display
will show:
** The lead/lag feature allows the customer to
choose one compressor as the “lead” compressor
and any others as the “lag” compressor (simulates
the mode of a sequencer). The lag compressor’s
on-line and off-line pressures are determined by
subtracting the lag offset set-point from the on-line
and off-line pressure set-points of the lead
compressor.

XXXX PSI 3.6 WARNINGS

OFFLINE AIR PRESSURE is the first set point
and XXXX stands for the value of the set point.
Press the SET button to select the set point to be
adjusted. Press the up or down arrow buttons to
raise or lower the set point value. Press the SET
button to move to the next set point. If the set
point value has been adjusted, press the SET
button to enter the new value. The display will
flash to acknowledge.The next set point will then
be displayed. If the value of the set point was not
changed, pressing the SET button will only step
to the next set point. When the SELECT
OPTIONS set point is entered, the SELECT
OPTIONS indicator will light, and the setpoints
for options Auto Start/Stop or Remote Start/Stop
will only be accessible and displayed if the option
module is installed in the unit. The Power Outage
Restart setpoints will only be accessible and
displayed if the combination Auto/Remote Start/
Stop/Power Outage Restart option module is
installed in the unit. The set point routine can be
exited by pressing the DISPLAY SELECT button
or exit will be automatic after 30 sec.
The following is a list of the set points. Also
included are maximum and minimum limits, step
size, and units of measure.
When a warning occurs, the alarm indicator will
flash and the display will alternate between the
current message and the warning message. If
multiple warnings exist, the message
SCROLL FOR WARN
will be substituted for the warning messages. The
up and down arrows can be used to obtain the
warnings
A warning needs to be reset by an operator. The
warning will clear when the SET button is
pressed once. The following is a list of the
warning messages.
1) CHG SEPR ELEMENT
This warning will occur if the pressure on the
separator is 12 psig (.8 bar) greater than the
pressure at the package discharge and the unit
is fully loaded.
2) HIGH AIREND TEMP
This will occur if the airend discharge
temperature exceeds 105°C (221°F).

MIN MAX STEP UNIT

OFFLINE PRESSURE 75 RATED + 3 1 PSI
ONLINE PRESSURE 65 OFFLINE - 10 1 PSI
CONTROL MODE MOD/ACS - MODULATION - ON/OFF LINE
DISPLAY TIME 10 600 10 SEC
AUTO RESTART OFF ON — —
AUTO RESTART TIME 2 60 1 MIN
SEQUENCER OFF ON — —
REMOTE START/STOP * OFF ON — —
POWER OUT/RESTART* OFF ON — —
POWER OUT RESTART 10 120 1 SEC
TIME *
DELAY LOAD TIME 0 60 1 SEC
LEAD/LAG** — — — —
LAG OFFSET 0 45 1 PSI
*Optional

24
3.7 ALARMS
10) CK MTR ROTATION
When an alarm occurs, the alarm indicator will
This alarm will occur if a unit is started and
light and display will show actual alarm message.
compressor has incorrect rotation.
If alternately multiple alarms have occurred the
display will show SCROLL FOR ALARM. In this 11) CALIBRATION FAIL
situation the up and down arrows will be used to This alarm will occur if the sensor calibration
view the alarm messages. All alarms (with the routine is executed and the sensor reading
exception of the emergency stop) will be reset by exceeds 10% of scale.
twice pressing the SET button. Any exceptions to
the above will be explained in the alarm 12) NO CONTROL POWER
description. This alarm will occur when the controller senses
The following is a list of the alarm messages. a loss of control power.
1) LOW SUMP PRESS 13) PRES SENSOR FAIL
This will occur if the unit is running and sump Whenever the pressure sensor is recognized as
pressure falls below 15psig (1.0 bar) missing or broken, a pressure sensor failure
alarm will occur.
2) HIGH AIR PRESS
INITIAL CHECK ALARMS
This will occur if the unit is running and sump
pressure is greater than unit rated operating 14) HIGH AIREND TEMP
pressure plus 20 psig (1.4 bar), plus the This will occur if airend discharge temperature is
separator pressure drop, or the line pressure is greater than 103°C (217°F).
15 psig (1.0 bar) above the rated pressure.
This alarm will only occur when the machine is
3) HIGH AIREND TEMP not running. When it occurs, the message MUST
This will occur if airend discharge temperature is COOL DOWN is added to the alternating group
greater than 109°C (228°F). of alarm messages.
4) STARTER FAULT 15) EMERGENCY STOP
This alarm will occur if the starter contacts open This will occur when the EMERGENCY STOP
while the unit is running. This alarm will also button is engaged. The alarm indicator will light
occur if the unit is given the stop command and and display will show:
the starter contacts do not open. EMERGENCY STOP
5) MAIN MTR OVERLD Disengage the EMERGENCY STOP button and
This will occur if a motor overload is sensed. press the SET button twice to reset this alarm.
6) FAN MTR OVERLOAD
This will occur if a fan motor overload is sensed.
7) TEMP SENSOR FAIL
This will occur when the temperature sensor is
recognized as missing or broken.
8) REMT STOP FAIL
This will occur if the momentary remote stop
switch does not disengage by the time the unit
attempts to start.
9) REMT START FAIL
This will occur if the momentary remote start
switch does not disengage by the time star-delta
transition occurs.

25
NOTES:

26
4.0 SYSTEMS
4.1 GENERAL SYSTEM INFORMATION
The SSR compressor is an electric motor driven,
single stage, screw compressor complete with
accessories piped, wired and baseplate
mounted. It is a totally self-contained air
compressor package.
A standard compressor is composed of the
following:
Inlet air filtration
Compressor and motor
Pressurized coolant system with cooler
Separation system
Capacity control system
Motor starting control system
Instrumentation
Safety provisions
Aftercooler
Moisture separator and drain trap
Optional accessories can provide for such things
as remote starting or stopping and sequencer.
4.2 AIR COOLED COMPRESSORS
Design Temperatures
The standard compressor is designed for
operation in an ambient range of 1.7°C. to 46°C.
(35°F to 115°F). When conditions other than
design levels described are encountered, we
recommend you contact your nearest Ingersoll-
Rand representative for additional information.
The standard maximum temperature 46°C
(115°F.) is applicable up to an elevation of 3300
ft. (1000 meters) above sea level. Above this
altitude, significant reductions in ambient
temperature are required if a standard drive
motor is to be used.
Coolant Cooler
The cooler is an integral assembly of core, fan
and fan-motor, mounted in the top section of the
compressor. The cooling air flows in through the
front corners of the enclosure, through the
horizontally mounted cooler cores, and
discharges upward through the top of the
enclosure.
Cooling Fan Motor
In a standard compressor, the cooling fan motors
are wired at the factory. They are three-phase-
motors. Each is protected by a fan motor starter/
overload. The fan motor is energized at the same
27
time the compressor drive motor is energized.
The fan motor starter/overload is wired in series
with the compressor drive motor overload. If an
overload occurs in the fan motor circuit, both the
fan motor and compressor drive motor will stop.
Aftercooler
The discharge air aftercooling system consists of
a heat exchanger (located at the cooling air
entrance of the machine), a condensate
separator, and an automatic drain trap.
By cooling the discharge air, much of the water
vapor naturally contained in the air is condensed
and eliminated from the downstream plant-piping
and equipment.
4.3 COOLANT SYSTEM
Coolant is forced by pressure from the receiver-
separator sump to the inlet port of the coolant
cooler and the bypass port of the thermostatic
control valve.
The thermostatic control valve controls the
quantity of coolant necessary to provide a
suitable compressor injection temperature. When
the compressor starts cold, part of the coolant
will bypass the cooler. As the system
temperature rises above the valve setting, the
coolant will be directed to the cooler. During
periods of operation in higher ambient
temperatures, all the coolant flow will be directed
through the cooler.
The compressor injection minimum temperature
is controlled to preclude the possibility of water
vapor condensing in the receiver. By injecting
coolant at a sufficiently high temperature,
temperature of the discharge air and lubricant
mixture will be kept above the dew point.
The controlled temperature coolant passes
through a filter to the airend under constant
pressure.
Each compressor has a hydraulic type full flow
filter with a single replacement spin-on element.
The filter is mounted on the oil filter/thermal valve
housing. It is rated at 4 microns.
There is a differential-pressure-bypass-valve set
to open in the event that the pressure drop
across the filter element rises to as high as 25
psi (1.8 BAR), which indicates an excessively
fouled element, as well as poor maintenance
practice.
4.4 COMPRESSED AIR SYSTEM
The air system is composed of:
1. Inlet air filter
2. Inlet valve
3. Rotors
4. Coolant/air separator
5. Minimum pressure/check valve
6. Aftercooler
7. Moisture separator/drain trap
Air enters the compressor, passing through the
inlet air filter and inlet valve.
Compression in the screw-type air compressor
is created by the meshing of two helical rotors
(male and female) on parallel shafts, enclosed in
a heavy-duty cast iron housing, with air inlet and
outlet ports located on opposite ends. The
grooves of the female rotor mesh with, and are
driven by, the male rotor. Tapered roller bearings
at the discharge end prevent axial movement of
the rotors.
The air-coolant mixture discharges from the
compressor into the separation system. This
system, self-contained in the receiver tank,
removes all but a few PPM of the coolant from
the discharge air. The coolant is returned to the
system and the air passes to the aftercooler. The
aftercooling system consists of a heat
exchanger, a condensate separator, and a drain
trap. By cooling the discharge air, much of the
water vapor naturally contained in the air is
condensed and eliminated from the downstream
plant-piping and equipment.
During unloaded operation, the inlet valve closes
and the blowdown solenoid valve opens,
expelling any compressed air back to the
compressor inlet.
4.5 COOLANT/AIR SEPARATION SYSTEM
The coolant/air-separation-system is composed
of a receiver with specially designed internals, a
two-stage, coalescing-type separator-element,
and provision for return of the separator fluid
back to the compressor.
Operation
The coolant and air discharging from the
compressor flow into the receiver through a
tangential discharge outlet. This outlet directs
the mixture along the inner circumference of the
receiver, allowing the coolant stream to collect
and drop to the receiver sump.
Internal baffles maintain the circumferential flow
of remaining coolant droplets and air. In an
almost continuous change of direction of flow,
28
more and more droplets are removed from the
air by inertial action and then returned to the
sump.
The air stream, now essentially a very fine mist,
is directed to the separator element. The
separator element is constructed with two
concentric, cylindrical sections of closely packed
fibers, each held in steel mesh. It is flange-
mounted at the receiver-outlet-cover.
The air stream enters the separator element
radially and the mist coalesces to form droplets.
The droplets collected on the outer first stage fall
to the receiver sump. Those collected on the
inner second stage collect near the outlet of the
element, and are drawn back to the compressor
inlet through a filter-screen and orifice fitting
installed in the separator scavenge line.
The air stream, now essentially free of coolant,
flows from the separator to the aftercooler, then
to the condensate separator, and on to the plant
air system.
4.6 ELECTRICAL SYSTEM
The electrical system of each SE compressor is
built around the microprocessor based Intellisys
controller.
The standard electrical/electronic components,
enclosed in a readily accessible enclosure
include:
1. SE Intellisys controller
2. Control transformers and fuses
3. Compressor and fan motor starters, with
auxiliary contacts and overload relays.
By use of a built-in Star-Delta type starter, the
compressor motor can be started and accelerated
using a greatly reduced “inrush” electric current.
The starter is completely automatic and controlled
by the Intellisys controller. Refer to the electrical
schematic, Section 8.0 schematic 8.1.
Options such as remote start/stop or power outage
restart with remote start/stop can be added by
installing a plug-in module in the controller.
4.7 CAPACITY CONTROL
The SE compressor is supplied with on-off line
control equipment.
Optional modulation control enables the
compressor to function with three operator
selectable capacity control systems, each designed
for different plant air requirements.
- Mod/ACS (modulation/automatic control sector)
- Modulation
- On-Off Line
The desired control is selected at the Intellisys
control panel (See Section 3.0).
Automatic Unloaded Start
The compressor will always start in the unload
mode. When unloaded, the inlet valve is nearly
closed, the blowdown solenoid valve is open (tank
vented), and the compressor is operating at
minimum power. The Intellisys will open the inlet
valve slightly to maintain the proper sump pressure
to insure positive oil flow and smooth, quiet
operation.
The minimum pressure check valve will prevent any
backflow of air from the plant air system during
unloaded operation.
On-Off Line Control
For those plants which have a widely varying air
demand, on-off line control will deliver air at full
capacity (compressor maximum efficiency
condition) or will operate at zero capacity
(compressor minimum power condition). The
compressor is controlled by the Intellisys,
responding to changes in plant air pressure. The
Intellisys opens the inlet valve and closes the
blowdown valve (3SV) whenever plant air pressure
drops below the on-line pressure set point. The
compressor will then operate to deliver full capacity
air to the plant system. If the plant air system
pressure rises to the off-line set point of the
Intellisys, the inlet valve closes and the blowdown
solenoid valve opens the receiver vent line, allowing
receiver pressure to drop. The compressor will
continue to run with minimum power draw.
Automatic Start-Stop
Many plant air systems have widely varying air Modulation/ACS Control (Optional)
demands or large air storage capacity which allows
For those plants which have relatively high
for automatic standby air capacity control.
constant air demand, relative to the compressor
During periods of low air demand, if the line capacity, the recommended control mode is
pressure rises to the offline set point, the Intellisys modulation.
begins to time out. If the line pressure remains
above the online set point for as long as the set The modulation control system retains the
time, the compressor will stop. At the same time the features of the on line-off line control, but
Automatic Restart light on the display panel will be provides for throttling of the inlet flow up to the
lit to indicate the compressor has shut down off line air pressure set point value.
automatically and will restart automatically, and the By applying line pressure to an adjustable
display will show “AUTO RESTART”. An automatic modulator valve, the throttling position of the
restart will occur when the line pressure drops to
inlet valve is controlled, thus allowing the
the online set point.
modulator to “trim” the inlet valve position as
The offline and online set points and shut down dictated by the line pressure.
delay time are set on the Intellisys control panel.
The modulating pressure range is about 4 psig
(0.3 BAR) and the modulator is factory set to
straddle the compressor rated pressure.
Modulation begins when the line pressure

29
reaches about 99 percent of the compressor
rated pressure and continues as/if the line
pressure rises. Modulation becomes stable
when the compressor output equals the plant air
demand. When the modulation is at the factory
setting, the maximum capacity reduction will be
approximately 60 percent of the compressor
rated capacity (as indicated in Figure 4.7-1).
If the air demand has decreased to a level below
the 60 percent modulated output, the line
pressure will increase slightly to actuate the
Intellisys. The compressor will then shift to the
off line control position, and operate unload with
the compressor vented.
It is sometimes desirable to begin modulation at
a higher pressure than the standard factory
setting, thereby increasing the modulated
capacity at the time the Intellisys is actuated.
Refer to Figure 4.7-1 for modulated capacities
available when this is done.
The compressor will then operate to deliver full
capacity air to the plant system. If the plant air
system pressure rises to that of the Intellisys off
line set point, pressurized air will be sent to the
inlet valve causing it to close, and to the
blowdown valve, causing it to open.
The compressor will continue to run unloaded,
but since pressure levels have reduced, it will do
so with a minimum power draw.
The Intellisys ® has a fixed minimum differential
of 10psi between the off line air pressure setting
and the on line air pressure setting. The
differential may be increased by adjusting the on
line air pressure setting of the Intellisys ® .
Refer to Section 3.5 for instructions.
The automatic control selector (ACS) is
designed to continuously monitor the plant air
demand and select either the on line-off line, or
the modulate control mode - whichever is most
desirable at anytime during an operating day.
It allows the compressor to operate in its most
efficient mode without attendance, thereby
reducing power costs to a minimum.
When the compressor operates in the on line-off
line control mode, the length of time the
compressor remains in the “off line” condition is
an indication of the plant air demand. Intellisys
controller is sensing and awaiting a sufficient
line pressure decrease before signaling a shift to
the on line mode. If the “off line” time period is
relatively short, thereby indicating a high
demand for air, it is preferable to shift the control
system to upper range modulation.
30
The Intellisys ® does this, and does it
automatically if the compressor unloads 3 times
within a 3 minute time period.
If later, the plant demand decreases, and even
under modulate control the line pressure
reaches the setting of the Intellisys ® controller,
and the control shifts to the “off line” mode, the
time in this mode will still be monitored. A long
“off line” time-period indicates a low plant air
demand, indicating the desirability of operating
in the on line-off line mode.
The Intellisys ® then does this, and does it
automatically if the compressor operates
unloaded for more than 3 minutes.
RATED OPERATING
MODEL
PRESSURE
XF 7.5 BAR/109 PSIG
EP 8.5 BAR/123 PSIG
HP 10 BAR/145 PSIG
XP 13 BAR/189 PSIG
Modulation Only
If MODULATION ONLY is turned on in the set
point routine, the unit will shift to Modulation
control mode immediately when the unit is
running. The 3 cycles within 3 minutes time
period required for ACS to change to Modulation
mode is bypassed. The unit will stay in
Modulation mode until the unit runs unloaded for
3 minutes (the unit then returns to ACS control)
or MODULATION ONLY is turned off via the set
routine.
Delay Load Time
This is the amount of time the line pressure must
remain below the online set point before the
compressor will load or start (if the unit was
stopped due to an auto start/stop situation).
Setting the load delay time to 0 will cause no
delay. When the delay load timer becomes
active, the display will switch to package
discharge pressure (if not displaying package
discharge pressure at that time) and then
display the delay load count down. Once the
count down reaches 0, the unit will load or start
and the display will return to line pressure. The
display select button is inactive during the delay
load count down.
Modulate Control Valve Adjustment
Insure that the compressor is isolated from
the compressed air system by closing the
isolation valve and venting pressure from the
drip leg.
Insure that the main power disconnect
switch is locked open and tagged.
1. Enter the setpoint routine and put the
compressor in the MODULATION mode.
Refer to Section 3.5 for instructions.
2. Remove 1/8" NPT plug from the tee in
the control piping on the side of the
support leg. Connect a pressure gauge
to this port.
3. Loosen the adjustment screw locknut
and back out adjusting screw 3 turns.
See Figure 4.7-2.
4. Open the isolation valve and start the
compressor.
5. Adjust the isolation valve to bring the
discharge air pressure to the rated
discharge pressure (7.5, 8.5, 10, 13
barg).
6. While MAINTAINING the rated discharge
pressure, turn the adjustment screw on
the modulation valve (see Figure 4.7-2)
so that the test pressure gauge reads:

13 psig for modulate 60% cfm

11 psig for modulate 70% cfm

Tighten the adjustment screw locknut.

7. Press UNLOADED STOP. Wait for sump

pressure to go 0 psig. Close the isolation
valve or bleed off all system air.
8. Enter the setpoint routine and put the
compressor in the desired control mode.
9. Remove the test pressure gauge and
replace the 1/8" NPT plug using Loctite
or similar threadsealant.

31
NOTES:

32
NOTES:

33
NOTES:

34
5.0 SCHEDULED PREVENTIVE MAINTENANCE

5.2 MAINTENANCE RECORDS 5.3 MAINTENANCE PROCEDURES

It is very important that you, the owner, keep accurate Before starting any maintenance, be certain the following
and detailed records of all maintenance work you perform is heeded.
on your compressor. This includes but not limited to
coolant, coolant filter, separator, inlet air filter, V- belts, 1 Read Safety Instructions
shaft seal and so forth. This information must be kept by 2. Use correct tools
you, the owner, should you require warranty service work 3. have recommended spares on hand
by Ingersoll-Rand representative. Maintenance record
sheets are located at the end of Instruction Section. SPECIAL NOTE:
REPLACE SEPARATOR ELEMENT WHEN THE
SEPARATOR DIFFERENTIAL PRESSURE ( D P )
REACHES THREE TIMES THE INITIAL PRESSURE
DROP OR MAXIMUM OF 0.8 bar (AT FULL LOAD OR
IF THE INTELLISYS WARNING”CHG SEPR
ELEMENT” IS DISPLAYED. SEE SECTION 3.9

35
5.4 SHEAVE ALIGNMENT

Any degree of sheave misalignment will result in a

reduction in belt life.

Misalignment of sheaves should not exceed 1/16” or

1.6mm.

Parallel misalignment occurs when the driven shafts are

parallel, but the two sheaves lie in different planes.

Angular misalignment occurs when the two shafts are

not parallel.

ALIGN SHEAVES

An easy and effective method of checking alignment in

both directions between the driver and driven sheaves
utilizes an accurate straight edge.

Lay the straight edge across the face of the driver (motor)
sheave and check alignment of the driven (airend) sheave.
Then lay the straight edge across the driven sheave and
check that the driver is aligned.

Alignment should be within 1/16” (1.6mm) maximum

when measuring the gap between the straight edge and
the rim of the opposite sheave in each direction.

The alignment is factory set and should only require

resetting if the drive motor or airend is removed. (For
example, motor or air end replacement.)

5.5 V-BELTS

Ensure that the compressor is isolated from the

compressor air system by closing the isolation valve and
bleeding pressure from the drip leg. Ensure that the main
power disconnect switch is locked open and tagged.

REPLACEMENT PARTS

V-belts (See Parts list)

DISASSEMBLY

Remove the doors of enclosure.

Remove the belt guard.

Loosen locknut on tensioning bolt located under the

subframe.

Remove the belts from the airend sheave and the motor
sheave (See section 5.6 for details).

36
INSTALLATION/INSPECTION

Inspect sheave grooves for foreign material or rubber

build-up. Clean degrease sheaves before installing new
belts to ensure long belt life.

Install new belts in the reverse order of disassembly.

When installing a new belt, do not pry or force the

belt over the sheave grooves (See section 5.6 to
tension the belt properly).

5.6 AUTOMATIC BELT TENSIONER SERVICE

Gas Spring & Drive Belt Replacement
Ensure that the compressor is isolated from the
compressor air system by closing the isolation valve
and venting pressure from the drip leg. Ensure that the
main power disconnect switch is locked open and
tagged.
The belts should be removed, discarded and new belts
and gas spring installed at the 8,000 hour interval or
two years - whichever comes first. To replace the gas
spring and belts, the following procedure to be
followed.
1. Remove the compressor belt guards.
2. Remove the J-hook, 5/8” screw and flat
washer from the installation tool kit. Place the hook end
of the installation tool (39908363) under the air end
support. Install flat washer (95947651) on screw
(54457148) and insert end of screw through slot in top
of mounting bracket on air end. Insert screw in
threaded nut on installation tool and turn screw
clockwise to compress the gas spring.Compress the
gas spring until the belts can easily slide over the
sheaves. Remove and discard the old V-belts.
3. Turn 5/8” screw on spring installation tool
counterclockwise untl the gas spring is fully extended.
Remove nuts from gas spring rod ends. Mark the
existing mounting holes in the air end support for new
spring installation. Remove gas spring.
4. Carefully install the new gas spring
(39592951) with rod end pointed down. Insert rod ends
in correct mounting holes in air end support. Gas
spring installation is to be as per the figure 5.6.1.
5. Turn 5/8” screw clockwise and compress gas
spring until new belts fit easily over sheaves. Install
new belts.
6. Loosen 5/8” screw until the gas spring fully
tensions the belts. Remove screw and J hook from
compressor. Rotate sheaves to properly seat belts.
“Do not leave tool in bracket” - This may damage
the automatic tensioner or prevent proper operation.

37
GAS SPRING INSTALLATION TOOL

GAS SPRING BRACKET LOCATION

DRIVE DRIVEN
UNIT LOCATION
SHEAVE SHEAVE

XF50 39856505 54422100 B2

EP50 39856505 54422118 B2

HP50 39856505 54422126 B2

XP50 39856505 54422076 C1

XF40 39856505 70613963 A1

EP40 39856505 70618855 A1

HP40 70618863 70618855 C1

XP40 70618871 70618855 C1

Figure 5.6.1

38
5.7 SHAFT SEAL REPLACEMENT

There are two lip type seals on the compressor. They are
wearable parts and should be replaced at 8,000 hours of
operation. While it is advisable to have your local Ingersoll-
Rand representative perform this work, the task can be
accomplished by a good mechanic following these
instructions.

Before beginning any work on the compressor, ensure

the main electrical disconnect is locked and tagged open
and that all air pressure is relieved from the system. See
warning labels printed overleaf.

Special Tools
- A clean work bench.
Replacemetn Parts
- Shaft seal kit (42486597).
- Loctite 609.

39
5.8 INLET AIR FILTER
The filter should be changed when the filter indicator
shows red.
The filter should be changed every 4000 hours or six
months whichever comes first, and more frequently in
dirty environments because coolant, coolant filter,
separator element, and airend life are a direct function
of how well you maintain and replace the inlet air filter.
To change the air filter, loosen the clamp that attaches
the filter to the inlet valve. Remove the filter. Install the
clamp on the new filter, attach the filter and tighten the
clamp.
5.9 COOLANT FILTER ELEMENT
The coolant filter element should be changed after the
first 150 hours of operation and every 2000 hours
thereafter, or when the coolant is being changed. In
dirty operation environments the filter should be
changed more frequently.
Use a suitable device and loosen the old element. Use
drain pan to catch any leakage during removal. Discard
old element.
Wipe the sealing surface of the filter housing with a
clean, lint-free rag to prevent the entry of dirt into the
system.
Remove the replacement element from its protective
package. Apply a small amount of clean lubricant on
the rubber seal and install the element.
Screw element on until the seal makes contact with the
head of the filter housing. Tighten approximately one-
half turn additional.
Start unit and check for leaks.
! CAUTION
Improper coolant filter replacement
will cause compresor damage.
Replace filter element after first 150 hours
operation and ever y 2000 hours
thereafter or when coolant is changed.
40
5.10 COOLANT
n SSR Ultra Coolant (Standard Factory Fill)
SSR Ultra Coolant is a polyglycol base coolant.
Change Ultra Coolant after every 8000 hours or every
two years, whichever comes first.
Items Required
In addition to the tools normally found in any reason-
ably equipped serviceman’s toolbox, the following
items should be available at the work site:
1) Suitable drain pan and container to hold
lubricant drained from unit.
2) A quantity of proper lubricant sufficient to refill
the compressor.
3) A minimum of one replacement coolant filter
element of the proper type for the unit to be
worked on.
There is a coolant drain hose supplied with each
compressor. It is supplied alongwith accessories when
shipped from the factory.
The coolant should be drained soon after the compres-
sor has been shut down. When the coolant is hot, the
drainage will be more complete and any particles in
suspension in the coolant will be carried out with the
coolant.
Hot coolant can cause severe injury. Use care
when draining separator tank.
To drain the unit, remove plug from drain valve located
on the bottom of the separator tank. Install supplied
drain hose and fitting assembly in end of drain valve
and place end of hose in a suitable pan. Open drain
valve to start drainage. After draining is complete, close
valve, remove hose and fitting assembly from valve, and
store in a suitable location for future use. Replace plug
in end of drain valve.
Do not store drain hose in starter box after it has
been used to drain the separator tank.
After the unit is drained and a new coolant filter ele-
ment is installed, refill the system with fresh coolant
through the filler cap on the side of the separator tank.
Bring the receiver level of coolant up to the top of the
sight glass. Replace the fill cap. Start the compressor
and allow it to run unloaded for a short time. The
correct coolant level is at the midpoint of the sight
glass with the unit running in the “UNLOADED” mode.
If the level is not near the midpoint, stop the compres-
sor and allow all pressure to relieve from the system.
Open the fill cap and add more coolant.
40/50 hp ..................................3.4 gallons (12.9 liters)
Replace the fill cap. Start the compressor and allow it
to run unloaded. The coolant level should now be near
the midpoint of the sightglass.
DO NOT OVERFILL THE MACHINE. Over filling will
affect separation and carryover down stream.
5.11 SEPARATOR TANK SCAVENGE
CHECK VALVE/SCREEN/ORIFICE
Tools Required
■ Open end wrench
■ Screwdriver

Procedure
Disconnect tubing at each end of check valve/screen/
orifice asembly.
Check orifice and clean if required. Use suitable small
screwdriver or knife and press screen retainer orifice
from its mating fitting (See Figure 5.11-1). Be careful
not to damage flared end of fitting or O-ring. Wash
screen and housing in safety solvent and blow dry.
Press the check valve/screen/orifice into fitting block.
Assemble the check vavle/screen/orifice assembly to
the tubing lines. The fitting must be re-installed with the
screen on the upstream side of the orifice as indicated
by the flow arrow (See Figure 5.11-1).

41
5.12 TEMPERATURE CONTROL VALVE ELEMENT
REPLACEMENT
Tools Required
Open end wrench
Procedure
Use suitable wrench to loosen temperature control
valve element. Ensure that excess stress is not
exerted on oil piping by holding oil filter/thermal valve
housing with appropriate tool while loosening element.
Remove faulty temperature control valve element.
Install replacement element. Start and load unit to
check for proper discharge temperature control.

5.13 COOLANT SEPARATOR ELEMENT

To check condition of separator element, run
compressor in full load mode and at rated pressure
and select “SEPARATOR PRESSURE DROP” in
L.E.D. Table. If display says “XX PSI”, then no
maintenance is required. If warning light is on and
display says “CHG SEPR ELEMENT” then the
separator should be replaced.
Loosen the fitting that holds the scavenge tube into
the tank and withdraw the tube assembly.
Disconnect blowdown valve from elbow in tank
cover.
Disconnect tube from fitting on minimum pressure
check valve. Loosen tube nut on same tube at
aftercooler inlet then swing tube away from tank
cover.
Use a suitable wrench and remove the bolts that
hold the tank cover in position. Remove cover by Inspect tank scavenge screen and orifice. Clean if
lifting up and away. necessary following instructions in Section 5.11.
Carefully lift the separator element up and out of Install scavenge tube down into the tank until the
the tank. Discard the faulty element. tube just touches the separator element. Tighten
Clean the gasket surface on both the tank and its fittings.
cover. Exercise care to prevent pieces of the old Install the regulation lines in their original position.
gasket from falling down into the tank.
Start unit, check for leaks, place in service.
Check the tank to be absolutely certain that no
foreign objects such as rags or tools have been
allowed to fall into the tank. Install replacement
element down into the tank after checking the new
element gaskets for possible damage. Center the
element up within the tank.
Place the tank cover in its correct position and
install bolts. Tighten the bolts in a cross-pattern
(Reference Figure 5.13-1) to prevent over-tighten-
ing one side of the cover. An improperly tightened
cover will likely result in a leak.
Tank Cover Bolt Torque Values
40/50 HP 1/2-13 UNC 80 ft.-Ib.(108 N-m)

42
5.14 COOLER CORES: CLEANING
Ensure that the compressor is isolated from the
compressed air system by closing the isolation
valve and venting pressure from the drip leg.
Ensure that the main power disconnect switch is
locked open and tagged. (See Figure 5.14-1).
Plug cooler inlet and outlet connections to prevent
possible contamination.
Remove cooler holding screws from cooler box and
remove cooler.
Cooler Cleaning
Flush the outside cooler core using a safety solvent.
Follow solvent manufacturer’s directions for proper use.
Reassemble in reverse order.
Make sure fan guards are replaced.
Refill the compressor with coolant. If contamination is
suspected, replace with new coolant.
Run compressor for ten minutes. Check for possible
leaks. Check coolant level.
Replace enclosure panels.

! CAUTION
Figure 5.14-1 MAIN DISCONNECT
LOCKED AND TAGGED Strong cleaners can harm aluminium
cooler parts. Follow cleaner
manufacturer’s instructions for use.
Tools Required Wear appropriate safety equipment.
Screwdriver
Wrench set
Air hose equipped with approved nozzle confirming to
relevent local standard.
On units sold outside India, consult local codes.
Inspection
Visually check the outside of the cooler cores to be
certain that a complete outside cleaning of the cooler is
required. Frequently dirt, dust or other foreign material,
may only need to be removed to remedy the problem.
When the cooler is covered with a combination of oil,
grease or other heavy substances that may affect the
unit’s cooling, then it is recommended that the cooler
cores be thoroughly cleaned on the outside.
Coolant Cooler
Remove panels.
Drain the coolant. See Section 5.10
Disconnect piping from cooler inlet and outlet ports.
Plug cooler inlet and outlet ports to prevent possible
contamination.
Remove cooler holding screws from cooler box and
remove cooler.
Coolant Cooler/Aftercooler
Remove panels.
Drain the coolant. See Section 4.6.
Disconnect tube from aftercooler inlet.
Disconnect tube from aftercooler outlet.
43
5.15 MOTOR LUBRICATION
Grease relief along shaft can occur, precluding neces-
The induction type squirrel cage motors haveartificial sity of removing this plug if inaccessible. The inlet
ball or roller bearings front and rear. At periodic inter- grease gun fittings and outlet plugs (or spring loaded
vals they require lubrication. reliefs) are located at each end of the motor housing.
Relubrication Interval The drive end reliefs protrude out of the circumference
of the lower portionof the end bell near a flange bolt.
1000 hrs................................................All TEFC drives. The drive end outlet plugs are located just behind the
(Or 9 months whichever comes first) flange in the air intake area.

1. Free drain hole of any hard grease (use piece

Improper lubricationcan be a cause of motor bearing
failure. The quantity of grease added should be care-
fully controlled. The smaller motors must be greased
with a lesser amount of grease than larger motors.
! CAUTION
Overgreasing can be a cause of
bearing and motor failure. make sure
dirt and contaminants are not
introduced when adding grease.
of wire if necessary).
2. Use hand lever type grease gun. Determine in
advance the quantity of grease delivered with
each stroke of the lever. A graduated cylinder
showing cubic centimeters (cc) may be used.
Or a 35mm film canister can give a close
aproximation of 2 cubic inches when filled.
3. Add the recommended volume of the recom-
mended lubricant. Do not expect grease to
appear at the outlet, but if it does, discon-
tinue greasing at once.

4. Run motor for about 30 minutes before replac-

Procedure for relubrication ing outlet plugs or reliefs. BE SURE TO SHUT
MOTOR DOWN, DISCONNECT POWER,
LOCK OUT AND TAG, AND REPLACE
! CAUTION THESE DRAIN FITTINGS TO PRECLUDE
LOSS OF NEW GREASE AND ENTRANCE
Grease should be added when the
OF CONTAMINANTS!
motor is stopped and power
discinnected.

Recommended Motor Grease

When regreasing, stop motor. Dicconnect power;
lockout and tag. Remove outlet plugs (or spring loaded
grease relief plugs if present). The outlet plug may not
be accessible on the fan end of some TEFC motors.
Most motor require:
Mobilith SHC 220..............................................Mobil
Use the grease as indicated on a special grease
information name plate on the motor. Use of alternative
greases can result in shortened motor life due to
incompatibility of greases.

Motor Bearing Maintenance (Stored Units)

To ensure that complete contact is maintained between
the motor bearings and the bearing grease on units to
be placed in storage for extended intervals, the follow-
ing motor maintenance procedure should be adhered
to:
1. Priot to placing unit in storage, rotate the motor
several revolutions by hand in the proper
direction of rotation.
2. Thereafter, rotate the motor as described in
step 1 at three month intervals until such time
as the unit is placec in service.

44
5.16 INTELLISYS REMOVAL
Ensure that the compressor is isolated from the
compressed air system by closing the isolation
valve and venting pressure from the drip leg.
Ensure that the main power disconnect switch is
locked open and tagged (See Figure 5.18-1).
Figure 5.18-1 MAIN DISCONNECT
LOCKED AND TAGGED
45
Tools:
Screwdriver Size #1, flathead
3/8 inch hex driver
Follow these precautions to minimize damage from
static electricity. Static can cause severe damage to
microcircuits.
1) Make the least possible movement to avoid build-ing
up static electricity from your clothing or tools.
2) Discharge potential static electricity by touching
(grounding) yourself to the starter box.
3) Handle circuit boards only by their edges.
4) Do not place the Intellisys® Controller on any metal
surface.
5) Leave the replacement parts in their protective bags
until ready for installation.
Before removing any components, open the starter box
door and check all wiring for tightness. A loose wire or
bad connection may be the cause of problems.
Controller Removal:
1) Open the starter box door.
2) Remove the 3/8” hex nuts attaching the controller to
the starter box door.
3) Remove the five wire connectors from the top of the
controller.
4) Remove the controller. Remove any option modules
which must be installed in the new controller.
5.17 COOLANT HOSES
The flexible hoses that carry coolant to and from the oil
cooler may become brittle with age and will require
replacement. Have your local Ingersoll-Rand represen-
tative check them every 2 years.
Ensure that the compressor is isolated from the
compressed air system by closing the isolation
valve and venting pressure from the drip leg.
Ensure that the main power disconnect switch is
locked open and tagged.
Removal
Remove enclosure panels.
Drain coolant into a clean container. Cover the con-
tainer to prevent contamination. If the coolant is
contaminated, a new charge of coolant must be used.
Hold fitting securely while removing hose.
Installation
Install the new hoses and reassemble the package by
reversing the disassembly procedure. Start the com-
pressor and check for leaks.
5.18 AIREND DISCHARGE HOSE
The flexible hose from the airend discharge to separa-
tor tank may become brittle with age and require
replacement. Check this hose as per the maintenance
schedule in Section 5.1.
Removal
Ensure that the compressor is isolated from the
compressed air system by closing the isolation
valve and venting pressure from the drip leg.
Ensure that the main power disconnect switch is
locked and tagged.
Disconnect hose nut from piping at each end of
discharge hose and remove. Hold fittings securely
while removing hose.

46

TROUBLE
Compressor fails to start.
Compressor shuts down.
NOTE: If a shutdown occurs,
press the DISPLAY SELECT
button once to activate the
L.E.D. display table. Using the
adjacent up and down arrows,
the values displayed will be
those immediately preceding
shut-down.
Use these values when trouble
shooting a problem.
Low system air pressure
Moisture separator trap drain stuck open.
6.0 TROUBLE SHOOTING CHART
CAUSE &/OR DISPLAY WHAT TO DO
— Check fuses. Check transformers
110/120V control voltage not available.
and wiring connections.
“STARTER FAULT”. — Inspect contactors.
“EMERGENCY STOP”. — Rotate emergency stop button to
“MAIN MTR OVER LD” or disengage, and press”SET” button
FAN MTR OVERLOAD” twice.
— Manually reset main or fan motor
“TEMP SENSOR FAIL”
over load relay, and press SET
“NO CONTROL POWER”
button twice.
— Check for defective sensor, bad
sensor connection, or broken
sensor wires.
— Check fuses and HAT switch
“HIGH AIREND TEMP.” — Insure that installation area has
adequate ventilation.
— Insure that cooling fan is
operating. If not reset circuit
breaker inside starter box.
— Check coolant level. Add if
required.
— Cooler cores dirty. Clean coolers.
“HIGH AIR PRESS.” — Check for restricted or
malfunctioning blowdown valve or
minimum pressure check valve.
— Check for air leak from tank or
“LOW SUMP PRESS.”
blowdown piping.
“PRES SENSOR FAIL” or — Check for defective sensor, bad
“TEMP SENSOR FAIL” sensor connection, or broken
sensor wires.
“CK MOTOR ROTATION.” — Interchange any two line
connections (L1,L2,L3) at the
starter.
“MAIN MTR OVERLD” — Check for loose wires.
— Check supply voltage.
— Check heater size.
“FAN MTR OVERLOAD” — Check for loose wires.
— Check supply voltage.
— Fan motor overload tripped
— Check for dirty cooler cores.
“STARTER FAULT.” — Inspect starter contactors.
— Check for loose wires.
“NO CONTROL POWER” — Check fuses and HAT switch
Compressor running in “Unload” Mode. — Press “UNLOAD/LOAD” button.
Controller off-line set point too low. — Press “UNLOAD/STOP” button,
set off-line set point at a higher
value.
Dirty air filter element. — Check filter condition. Replace as
required.
Air leak. — Check air system piping.
— Inspect and repair.
47
 6.0 TROUBLE SHOOTING CHART (Continued)
TROUBLE
Low system air pressure
(continued)
High coolant consumption/
coolant in air system
Water in Air System
Excessive noise level
Excessive vibration
Shaft Seal leak
Black residue on belt guards
Pressure relief valve opens
CAUSE &/OR DISPLAY
Inlet valve not fully open.
System demand exceeds
compressor delivery
Excessive coolant level.
Plugged separator element.
Separator element leak.
Plugged separator scavenge
orifice/screen
Compressor operating at low
pressure (75 psig or below).
Coolant system leak.
Defective moisture separator/
drain trap
Trap drain or drain piping
plugged.
Aftercooler core dirty.
Enclosure panels not in place.
Drain line/drip leg incorrectly
installed.
No refrigerated or desiccant dryer
in air system
Compressor defective. (Bearing
failure or rotor contact.)
Enclosure panels not in place.
Loose component mounting.
Loose components
Motor or compressor bearing
failure.
External sources.
Defective shaft seal.
Sheaves mis-aligned.
Excessive belt wear
Compressor operating over
pressure.
Defective valve.
48
WHAT TO DO
— Inspect and repair. Check control system
operation.
— Install larger or an additional compressor.
— Check level, lower if necessary by draining.
— Check separator pressure drop.
— Check separator pressure drop. If low,
replace element.
— Remove and inspect orifice/screen. Clean if
required.
— Operate at rated pressure.
— Reduce system load.
— Inspect and repair leaks.
— Inspect and clean if required. Replace
separator/trap if defective.
— Inspect and clean.
— Inspect and clean.
— Install enclosure panels.
— Slope drain line away from trap. Install drip
leg.
— Contact local Ingersoll-Rand Distributor or
Air Center.
— Contact authorized Distributor immediately,
do not operate unit.
— Install enclosure panels.
Inspect and tighten.
— Inspect and tighten.
— Contact authorized Distributor immediately,
do not operate unit.
— Inspect area for other equipment.
— Replace per this manual or contact
authorized Distributor.
— Align sheaves.
— Replace belts.
— Adjust Intellisys set points.
— Replace valve.
7.0 OPTIONS
7.1 REMOTE START/STOP
The remote start/stop option allows the operator ! WARNING
to control the compressor from a remote
mounted start/stop station. This option may be
This machine is remote Disconnect power before
factory installed or a field installation kit is servicing.
start/stop equipped.
available. This option is a plug-in module.
With the optional plug-in module installed, two May start or stop at any Lock and tag out.
different switches can be wired to the Intellisys time.
for remote start/stop. Refer to (Electrical
Schematic 8.1 for wiring location). The switches Can cause severe injury See Operators/Instruction
or death. manual.
are customer supplied and must be of the
momentary type. The stop switch contacts are
normally closed and start switch contacts are
normally open.
7.2 REMOTE START-STOP AND POWER
OUTAGE RESTART OPTION
When remote start-stop and the Power Outage
Restart Option is desired, a combination field
installation kit that contains these features is
available. The option includes a plug-in module
and all of the hardware necessary.
The Power Outage Restart portion of the option
is for plants that have interruptions in their
incoming power supply to the compressor and
must maintain an uninterrupted supply of
compressed air. When turned on, the option
allows the compressor to automatically restart
and load 10 seconds after incoming power is
restored after a power interruption.
7.3 MODULATION CONTROL
When modulation control is desired, a field
installation kit that contains items required to
convert online/offline units to modulation or
modulation/ACS mode is available. The
installation drawing of this module is shown in
the parts list section of this manual.
7.4 HIGH DUST FILTRATION
If your compressor is exposed to constant dusty
environment, it is advisible to go for high dust
inlet filtration option. This option may be factory
installed or can be bought as a kit. The
installation drawing is shown in the parts list
section of this manual.

49
Notes:

50
8.0 REFERENCE DRAWINGS

Electrical, schematic
Foundation plan
Basic flow, schematic
Typical system flow diagrams

51
8.1 ELECTRICAL, SCHEMATIC

52
8.1 ELECTRICAL, SCHEMATIC

53
8.2 FOUNDATION PLAN

54
8.2 FOUNDATION PLAN

55
8.3 BASIC FLOW, SCHEMATIC - STAR-DELTA

56
8.3 BASIC FLOW, SCHEMATIC - STAR-DELTA WITH MODULATION

57
8.5 TYPICAL SYSTEM FLOW DIAGRAMS

58
59
60
61
62
9.0 MAINTENANCE RECORD
DATE RUN TIME WORK DONE QTY. UNIT WORK
HRS. MEASURE BY

49
DATE RUN TIME WORK DONE QTY. UNIT WORK
HRS. MEASURE BY

50
DATE RUN TIME WORK DONE QTY. UNIT WORK
HRS. MEASURE BY

51
DATE RUN TIME WORK DONE QTY. UNIT WORK
HRS. MEASURE BY

52
 ¨

XF/EP/HP/XP 40/50
PARTS LIST AND RECOMMENDED
SPARES

Before installation or starting the compressor for the

first time, this manual should be studied carefully to
obtain a clear knowledge of the unit and of the duties
to be performed while operating and maintaining the
unit.

RETAIN THIS MANUAL WITH UNIT.

This Technical manual contains IMPORTANT SAFETY
DATA and should be kept with the air compressor at all
times.

EFFECTIVE

FROM June, 2000

TO
PAN-IBPL (R0)
June, 2000

53
 CONTENTS
Assembly, Intellisys/Starter..................................56
Assembly, Intellisys/Starter with Modulation........58
Assembly, Star Delta............................................60
Assembly, Major Components..............................62
Assembly, Airend Piping.......................................64
Assembly, Inlet Valve - Star Delta.........................66
Assembly, Filter - Heavy Duty...............................68
Assembly, Separator Tank....................................70
Assembly, Air Cooled Cooler with Aftercooler......72
Assembly, Standard Enclosure.............................74
Recommended Spare Parts.................................76
ROTARY SCREW AIR COMPRESSOR
This unit was purchased from
______________________________________________
______________________________________________
______________________________________________
Ingersoll-Rand Company reserves the right to make
changes or add improvements without notice and
without incurring any obligation to make such changes
or add such improvements to products sold previously.
No. of units on
order:___________________________________
Customer Order
No.:___________________________________
Ingersoll-Rand Co. Order
No.:____________________________
For ready reference:
Record the serial number and model number of your
unit here.
Serial
Number:________________________________________
Model
Number:_______________________________________
PARTS LIST

INTRODUCTION
GENERAL
This manual, which contains an illustrated parts
breakdown, has been prepared as an aid in identifying
and ordering parts in the SSR compressor. All of the
compressor parts listed in the parts breakdown are
manufactured with the same precision as the original
equipment.
Ingersoll-Rand service facilities and parts are
available worldwide. There are Ingersoll-Rand branch
offices and authorised distributors located in the
principal cities of India. There are also Ingersoll-Rand
subsidiaries and authorised distributors located in the
principal cities throughout the world.
HOW TO ORDER PARTS
In order that all avoidable errors be eliminated when
ordering parts, please specify the following:
1. The model number of the unit as shown on
the Compressor data plate.
2. The serial number of the unit as shown on
the Compressor data plate.
3. The form number of this manual (can be found
on the right bottom corner of the first page
with rev. level)
4. The reference number, part number descrip-
tion and quantity needed exactly as listed.

DESCRIPTION 5. The motor data code shown on the motor data

plate.
The illustrated parts breakdown illustrates the various
assemblies and detailed parts which make up this
particular SSR compressor. A series of illustrations
show each part clearly and in it’s correct location
relative to the other parts in the illustration. Each part
on an illustration is referenced with a number,
description and quantity needed per assembly is listed
in numerical order on the following pages.
OPTIONAL EQUIPMENT
Several optional accessories/items are available for
convenience or special application. These accessories
have been selected as being particularly suitable for
use on the SSR compressor.
For complete details on Optional Equipment, contact
your sales representative.
HOW TO USE THIS PARTS MANUAL
1. Turn to the Parts Section to locate the desired
illustrations.
2. Locate the parts on the illustration by visual
identification and the reference number.
3. Find the referenced number on the tabulated
page, along with the part number and
description.
 39908462
Reference
Rev. 03
56
 Assembly, Intellisys/Starter Box/Control Piping (Star Delta without Modulation)
Ref.No. Part No. Qty Description Ref.No. Part No. Qty Description

*1 70195644 1 Switch, Emergency Stop

39497847 xxx Tubing, .25 Teflon (XP Units)
2 39817655 1 Controller, Intellisys
15 39583943 1 Valve, Solenoid 3-Way (10SV)
2A 39128533 10 Nut
*16 70569926 1 Fitting end
2b 39495874 1 Gasket, Intellisys/starter box
*17 70569934 xxx Conduit
3 39191655 1 Plug, 16 Position
*18 70569868 xxx Conduit
4 39186101 1 Plug, 4 Position
*19 70569850 3 Fitting end
5 39191630 1 Plug, 5 Position
20 39853809 1 Transducer, Pressure
6 39186093 1 Plug, 6 Position
22 39155478 2 Elbow
7 39191648 1 Plug, 11 Position
24 39818869 1 Box, Intellisys
*9 70612957 2 Nipple
26 39195235 1 Plug
57

11 39130000 1 Plug
27 39418926 1 Valve, solenoid 3-way (1SV)
12 39155577 2 Elbow
28 39140785 1 Plug
13 39156393 2 Connector
14 39124813 xxx Tubing, .25 Synflex (XF, EP, HP, Units)

Note:
1. Standard Fasteners such as nuts, bolts and screws are listed as sub-items
2. XXX - Order per number of inches required.
3. * Part number is different if used in Davidson.
 39830120
Reference
Rev. 10
58
 Assembly, Intellisys/Starter Box/Control Piping (Star Delta with Modulation - Option)
Ref.No. Part No. Qty Description Ref.No. Part No. Qty Description

*1 70195649 1 Switch, Emergency Stop

*18 70569868 xxx Conduit
2 39817655 1 Controller, Intellisys
*19 70569850 3 Fitting end
2A 39128533 10 Nut
20 39853809 1 Transducer, Pressure
2B 39495874 1 Gasket, Intellisys/starter
*23 95837233 1 Plug
3 39191655 1 Plug, 16 Position
24 39156468 1 Tee, adapter
4 39186101 1 Plug, 4 Position
25 39199476 1 Valve, regulator (XF, EP, HP Units)
5 39191630 1 Plug, 5 Position
39199484 1 Valve, regulator (XP Units)
6 39186093 1 Plug, 6 Position
26 95047908 1 Nipple
7 39191648 1 Plug, 11 Position
27 39198012 1 Connector, Bulk head
*9 70612957 4 Nipple
28 39155478 3 Elbow
59

11 39530852 1 Valve, solenoid - 2way (2SV)

29 95930301 1 Bushing
12 39155577 4 Elbow
30 95343679 1 Nipple
13 39156393 2 Connector
31 39127261 1 Valve, shuttle
14 39124813 xxx Tubing, .25 Synflex (XF, EP, HP, Units)
33 39818869 1 Box, Intellisys/starter
39497847 xxx Tubing, .25 Teflon (XP Units)
35 39195235 1 Plug
15 39583943 2 Valve, Solenoid 3-Way (10SV/6SV)
36 39156385 1 Tee
*16 70569926 1 Fitting end
38 39418926 1 Valve, solenoid - 3 way (1SV)
*17 70569934 xxx Conduit
39 39140785 1 Plug

Note:
1. Standard Fasteners such as nuts, bolts and screws are listed as sub-items
2. XXX - Order per number of inches required.
3. * Part number is different if used in Davidson.
 39907258
Reference
Rev. 01
60
 Assembly, Starter - Star Delta

Ref.No. Part No. Qty Description

2 39190939 1 Lug, Ground

2A 39141809 1 Screw
2B 39128541 1 Nut
*3 70557855 2 Contactor, Power (1M/2M)
*3A 70193057 1 Coil, (1M/2M)
*6 70183868 1 Contactor, Power (1S)
*6A 70193057 1 Coil
*9 70551577 1 Overload Relay
*11 70518964 1 Light, Power-On
61

*12 70557830 1 Transformer, Control

*13 70567557 4 Block, Terminal
*13A 70569835 2 Stop, terminal block
*14 70557848 1 Starter, Manual Motor
*16 81318933 5 Fuseholder
*18 81279093 2 Fuse, 4A (1FU/2FU)
*19 81310633 1 Fuse, 6A (3FU)
*20 70195615 2 Fuse, 2.0A (4FU/5FU)
21 39203443 1 Suppressor, Arc

Note:
1. * Part number is different if used in Davidson.
 39933114
Reference
Rev. B
62

SHEAVES LIST
DRIVE DRIVEN
UNIT
SHEAVE SHEAVE

XF50 39856505 54422100

EP50 39856505 54422118

HP50 39856505 54422126

XP50 39856505 54422076

XF40 39856505 70613963

EP40 39856505 70618855

HP40 70618863 70618855

XP40 70618871 70618855

 Assembly, Major components
Ref.No. Part No. Qty Description Ref.No. Part No. Qty Description

1 39905047 1 Base 12A 39133145 1 Screw

2 54412861 1 Angle, belt guard 12B 39128434 1 Screw

2A 39133145 1 Screw 12C 39128541 1 Screw

2B 39128434 1 Screw 13 54412895 1 Sub Frame

2C 39128541 1 Nut 13A 39178678 16 Screw

3 54412945 1 Guard 14 54516398 1 Screw, Tensioning

3A 39133145 2 Screw 14A 95922910 1 Nut

4 54412929 1 Guard 15 93469955 1 Motor, 50HP

4A 39133145 4 Screw 70613708 1 Motor, 40HP

**5 xxxxxxxx 1 Sheave, driver 16 39573670 1 Hose

5A 95092755 1 Bushing 17 39139563 1 Elbow

6 54412838 2 Leg, long 18 xxxxxxxx 1 Assembly, Starter

63

6A 39178678 6 Screw 18A 39178678 4 Screw

7 54412820 2 Leg, short 19 54419643 1 Support, Starter

7A 39178678 6 Screw 19A 39178678 4 Screw

**8 xxxxxxxx 1 Sheave, driven 20 xxxxxxxx 1 Assembly, Separator Tank

8A 54422605 1 Retainer, sheave 20A 39116330 2 Screw

8B 39179072 1 Screw 21 39191366 5 V-Belt, 71” (XF,EP,HP,XP units)

8C 54422613 1 Spacer 24 54432752 4 Spacer, Motor (200FR)

9 xxxxxxxx 1 Assembly, Airend/Piping 24A 95929121 4 Screw

9A 39191283 4 Bolt 24B 95923355 4 Nyloc nut

10 54412887 1 Bracket, Gas Spring *26 70569934 36” Conduit

10A 96702279 3 Screw 28 54412937 1 Guard, Belt, Right Rear

11 39592951 1 Spring, Gas

Note:
11A 39128558 2 Nut
1. Standard Fasteners such as nuts, bolts and screws are listed as sub-items
12 54412846 1 Angle, Belt Guard
2. * Part number is different if used in Davidson.
3. ** Sheave part numbers and gas spring location details are given in the previous page.
 39933130
Reference
Rev. B
64
 Assembly, Air End Piping
Ref.No. Part No. Qty Description

1 54441522 1 Orifice
2 93481562 1 Manifold
3 95989695 1 Connector
4 54423520 1 Tube, Oil Feed
5 96739701 1 Connector
6 54440458 1 Gasket, Air Discharge
7 54471818 1 Adapter, Air Discharge Plate
7A 39179080 4 Bolt
8 39139563 1 Elbow, 45°
65

9 37952439 1 Sensor, Temperature

10 37952264 1 Switch, High Air Temperature
*12 70570932 1 Coupling
*13 70569870 1 Fitting end
*14 70569868 32” Conduit
15 39311618 1 Elbow
16 54461066 1 Adapter

Note:
1 * Part number is different if used in Davidson.
 39933171
Reference
Rev. A
66
 Assembly, Inlet Valve - Star Delta
Ref.No. Part No. Qty Description

1 36889202 1 Gasket, Inlet Valve

2 54439112 1 Adapter, Inlet Valve
2A 39310271 4 Screw
3 39496591 1 Gasket, Inlet Valve
4 39840418 1 Valve, Inlet-Star Delta
4A 35273416 6 Screw
4B 39204854 6 Washer
5 39155478 1 Elbow
67

5A 39124813 xxx Tubing, .25 Synflex (XF,EP,HP Units)

5B 39497847 xxx Tubing, .25 Teflon (HXP Units)
6 39124722 1 Indicator, Air Filter
8 97134456 1 Clamp, Band
9 39588777 1 Filter, Air, Standard
10 39317060 1 Silencer
11 39306485 1 Adapter
12 39184510 1 Plug

Note:
1. XXX - Order by the number of inches required
2. * Part number is different if used in Davidson
 39828843
Reference
Rev. 06
68
 Assembly, Filter - Heavy Duty (Option)
Ref.No. Part No. Qty Description

2 39852439 1 Hose, Air Inlet

3 39196670 1 Tubing, Air Intake
4 39196662 1 Elbow, 90° Rubber
5 39821640 1 Filter, Heavy Duty
6 39144027 2 Clamp, Filter
6A 39128434 4 Screw
6B 39128541 4 Nut
7 39497011 2 Bracket, Filter Mounting
69

7A 39133152 4 Screw
8 39213798 4 Clamp, Band

Note:
1. Standard fasteners such as nuts, bolts and screws are listed as sub-items.
 39933148
Reference
Rev. A
70
 Assembly, Separator Tank
Ref.No. Part No. Qty Description Ref.No. Part No. Qty Description

15 39417118 1 Adapter
1 39889498 1 Tank, Separator
16 39796594 1 Tube, Scavenge
2 39831888 1 Element, Separator
17 39303219 1 Orifice
3 39588017 1 Valve, Relief (XF,EP,HP, &XP Units)
18 39572409 1 Hose, Tank Scavenge
4 39156435 2 Connector, Synflex
19 95948758 1 Elbow
5 39124813 xxx Tubing, Synflex (XF,EP,HP Units)
20 39136932 1 Valve, Blowdown
39497847 xxx Tubing, Teflon (XP Units)
21 39476668 1 Tubing, Blowdown
*6 70614755 1 Valve, Drain
22 39479944 1 Union
*7 70614763 1 Elbow
23 39475637 1 Valve, Minimum Pressure Check
8 95938171 1 Elbow
24 39128624 1 Adapter
9 39573043 1 Hose, Oil Filter To Manifold
71

25 39575147 1 Hose, Blowdown (Star Delta Units)

*10 70561576 1 Sight Glass
26 95948758 1 Elbow (Star Delta Units)
11 39478953 1 Plug, Oil Fill
*27 70569850 1 Fitting end
12 39139563 1 Elbow, 45° Tank Inlet
*28 70569868 47” Conduit
13 39573670 1 Hose, Airend Discharge
**29 97114268 1 Plug
14 95937496 1 Adapter

Note:
1 * Part number is different if used in Davidson.
2. ** Does not appear in Davidson drawing
 39933122
Reference
Rev. B
72
 Assembly, Air cooled Coolers with Aftercoolers
Ref.No. Part No. Qty Description Ref.No. Part No. Qty Description

1 39905047 1 Base 17 39905286 1 Tube, Thermo Valve To Oilcooler

2 92667534 1 Motor, Fan 18 95368890 1 Elbow
2A 39110309 4 Screw 19 39566237 1 Housing, Thermo Valve/Oil Filter
2B 39128566 4 Nut 20 95955860 1 Connector
*3 70569850 1 Fitting end 21 35225085 2 Clamp, Tube
*4 70569868 34” Conduit *22 39184510 1 Plug
5 54412879 1 Support, Fan Motor 23 95937843 1 Tee, Swivel
5A 39116330 4 Screw 24 39441944 1 Element, Thermo Valve
5B 39116348 4 Nut 25 39907175 1 Filter, Oil
6 54441498 1 Fan, 24” 26 39152368 1 Elbow
*7 70616321 2 Guard, Fan 28 54446539 2 Tube, Aftercooler To Moisture Separator
7A 39133152 8 Screw 29 95949749 2 Elbow
73

7B 95929071 8 Washer 30 39906334 1 Separator, Moisture

**7C 39128426 2 Screw 31 39819834 1 Tube, Moisture Separator To Base Out
8 39819289 1 Angle, Cooler Support 32 39155478 1 Elbow
8A 39133145 6 Screw 33 39124813 xxx Tubing, .25 Synflex (XF,EP,HP Units)
9 54423173 1 Box, Cooler 39497847 xxx Tubing, .25 Teflon (XP Units)
*9A 70561550 xxx Gasket strip 34 39159082 1 Elbow
10 39572094 1 Hose 35 39137542 1 Connector, Barbed
11 39128673 2 Elbow 36 39137534 1 Elbow, Barbed
12 39580055 1 Valve, Check 37 54421698 1 Drain Trap
13 39899901 1 Cooler, Oil/Aftercooler 38 54423280 1 Union, Trap
13A 39133152 8 Screw 39 39137518 13.5” Tubing, .38 Synflex
13B 95929071 8 Washer
Note:
14 39111752 2 Connector
1. Standard fasteners such as screws and nuts are listed as sub-items.
15 54446521 1 Tube, Aftercooler To MPCV 2. xxx Order per number of inches.
16 54423702 1 Tube, Oilcooler To Thermo Valve 3. * Part number is different if used in Davidson.
4. ** Does not appear in davidson drawing.
 39933155
Reference
Rev. A
74
 Assembly, Standard Enclosure
Ref.No. Part No. Qty Description Ref.No. Part No. Qty Description

1 39905047 1 Base 11 54419650 1 Assembly, upper front panel

2 39480470 4 Cover, fork lift 54419601 1 Panel, upper front
2A 39133145 8 Screw 54419577 1 Foam, upper front panel
3 54419718 1 Assembly, rear panel 11A 39133145 4 Screw
54419585 1 Panel, rear 12 39224936 1 Assembly, top front panel
39820865 1 Foam, rear panel 39869300 1 Panel, top front
3A 39142690 2 Screw 39869318 1 Foam, top front panel
3B 35256452 2 receiptable, clip on 12A 39142690 4 Screw
4 54419692 1 Assembly, right rear corner 12B 35256452 4 Receiptable, clip on
54419619 1 Corner, rear 13 39869292 1 Angle, left side
39820816 1 Foam, side rear corner 13A 39133145 4 Screw
39820899 1 Foam, rear corner 14 39820394 1 Plenum, left side
4A 39133145 6 Screw 14A 39133145 2 Screw
5 54419700 1 Assembly, left rear corner 15 39820428 1 Plenum, right side
54419619 1 Rear corner 15A 39133145 2 Screw
39820816 1 Foam, rear corner 16 39229240 1 Assembly, top rear panel
39820899 1 Foam, rear corner 39824255 1 Panel, top rear
75

5A 39133145 6 Screw 39820832 1 Foam, top rear panel

6 54419726 2 Assembly, common panel 16A 39142690 4 Screw
54419593 1 Panel, common 16B 35256452 4 Receiptable, clip on
39820873 1 Foam, common panel 17 39824248 1 Angle, rear
7 54419684 1 Assembly, right front corner 17A 39133145 2 Screw
54419627 1 Corner, right front 18 39820725 1 Plenum, rear
39820808 1 Foam, side front corner 18A 39133145 2 Screw
39820881 1 Foam, front corner 19 39485818 1 Plug
7A 39133145 7 Screw 20 39820923 2 Grill, intake
8 54419676 1 Assembly, left front corner *20A 39133152 12 Screw
54419635 1 Corner, left front **20B 95929071 12 Washer, flat
39820808 1 Foam, side front corner 21 39133954 4 Latch, door
39820881 1 Foam, front corner **Ref. 70561550 xxx Gasket, strip
8A 39133145 7 Screw
9 39869326 1 Angle, right side
9A 39133145 4 Screw Note:
10 39825617 2 Guard, exhaust
*10A 39133152 8 Screw 1. Standard fasteners such as screws and nuts are listed as sub-items.
10B 35256452 8 Receiptable, clip on 2. xxx Order per number of inches.
**10C 95929071 8 Washer, flat 3. * Part number is different if used in Davidson.
4. ** Does not appear in davidson drawing.